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Commits
| Author | SHA1 | Message | Date | |
|---|---|---|---|---|
  jakman85andClaude Opus 5
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cf33338448 |
feat(node_health): detect the EFI memattr bug on every run, two independent ways
The fault is BOOT-TO-BOOT NON-DETERMINISTIC — the same machine booted correctly two boots
earlier — so it has to be detected on every health run, not diagnosed once. And node 1 is
exposed to the identical lottery on every reboot while currently looking healthy.
firmware.efi_memattr — reads the kernel ring buffer and distinguishes six states:
Failed to map EFI Memory Attributes table @ 0x.. -> FAIL (memory lost NOW)
Unexpected EFI Memory Attributes table version <N> -> WARN (corrupt table still published;
intact only by luck)
[Firmware Bug]: Corrupted EFI ... detected! -> PASS (the >=6.13 fix working)
no memattr line, log reaches early boot -> PASS (no table / accepted / not UEFI)
no memattr line, log does NOT reach early boot -> SKIP
dmesg unreadable -> SKIP
memory.physical_total — deliberately a SEPARATE check, not folded in: it measures the SYMPTOM
with no kernel log at all, so an unreadable-dmesg node is still not unmeasured. Two sub-verdicts,
worst wins: /proc/zoneinfo present-vs-managed (world-readable, works on metal and VMs — sum of
managed IS MemTotal) and MemTotal vs the DIMM total from dmidecode. Thresholds 10% WARN / 25%
FAIL, set from measured baselines: 2.0% prod-1, 2.1% workstation, 2.2% dev VM, vs 83.4% prod-2.
THREE GUARDS AGAINST A FALSE PASS, because "no memattr line" must never silently mean "fine":
1. dmesg failure yields available:false with the exact reason (rc, uid, kernel.dmesg_restrict) -> SKIP
2. the ring buffer WRAPS and every memattr line prints in the first fraction of a second, so the
collector records a boot_covered anchor (Linux version / BIOS-provided physical RAM map); no
memattr line WITHOUT that anchor is a SKIP, not a PASS
3. memory.physical_total needs no kernel log at all
Verified by forcing the unprivileged path: SKIP with the EPERM reason while zoneinfo still PASSed.
VERDICTS, confirmed live:
k3s-prod-1 WARN "EXPOSED, not immune ... survived only because its garbage version field read
1030, which is > 2 ... one unlucky boot from the failure state" + PASS 2.0%
k3s-prod-2 FAIL "THIS NODE HAS LOST MEMORY TO THE BUG ... at 0xbeeb0018" + FAIL 83.4%/83.6%
k3s-dev-* PASS both, NO false finding: "no UEFI config-table line ... did not boot via UEFI.
Log reaches back to early boot, so that absence is measured, not assumed."
Both failure texts carry the remediation verbatim, including that there is NO kernel cmdline
workaround because efi_memattr_init() runs before any efi= bail-out.
Root-gating follows the role's existing pattern: --privileged re-runs THE SAME collector under
become, only when the unprivileged pass actually failed to read something. Reimplementing the log
grep and SMBIOS parse in Jinja would have been a second source of truth for the same fact.
LATENT BUG FIXED in passing: the collector's run() used bare shutil.which(), so dmidecode (in
/usr/sbin) was invisible under the unprivileged k3s PATH and produced a FALSE "not installed"
skip reason. Now shares the sbin-aware which() collect_tools() already had.
INCIDENTAL FINDING recorded in §0b: node 1's DIMMs are NOT a matched pair — DIMM1 Micron
8ATF2G64HZ-3G2E1 (DDR4-3200), DIMM3 Micron 16ATF2G64HZ-2G6E1 (DDR4-2667). Both 16 GB so capacity
is right, but different rank organisation and rated speed, so the pair runs at 2667. Not a fault;
recorded because §2 requires the three nodes to end up symmetric and "2×16 GB Micron" hid it.
Serves: R-ENV-01, R-ENV-03, R-OBS-04. Task: T-7.1.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
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jakman85andClaude Opus 5
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0b3db6e778 |
fix(node_health): SMART verdict was wrong by 4096x — judge on portable signals
The first real SMART run FAILED k3s-prod-1's drive on reallocated=61440. That verdict
was WRONG, and the failure mode is instructive: the check trusted a VENDOR-DEFINED raw
value as if it were an ATA-standard sector count.
Micron TN-FD-20 ("SMART Attributes for the C400 SSD") names attribute 5 "Reallocated
BLOCK Count" and defines its raw as grown-bad-blocks x Block_Sector_Count, where
Block_Sector_Count is 256 x 16 = 4096 for the 128Gb-NAND parts (256GB/512GB). This is
the 512GB C400-MTFDDAC512MAM: 61440 / 4096 = 15. Triply corroborated on the drive itself
— attr 170 Grown_Failing_Block_Ct = 15, attr 196 Reallocated_Event_Count = 15, attr 5
normalised value 100 against thresh 10, and `when_failed` empty on every attribute.
FIFTEEN grown bad blocks, not sixty-one thousand bad sectors.
smartctl(8) states it outright: since ATA/ATAPI-4 rev 4 the meaning of raw Attribute
fields is "entirely vendor-specific". So a raw value can never be a portable verdict.
FAIL now comes only from signals that mean the same thing on every drive: the drive's own
smart_status.passed; NORMALISED value vs the MANUFACTURER's own threshold via smartctl's
when_failed ("now"/"past"/""), split Pre-fail -> FAIL and Old_age-or-past -> WARN; the
ATA-standard counters 197/198/187 (199 CRC is WARN-only — it is link, not media); and for
NVMe critical_warning / media_errors / percentage_used. Wear reads from the NORMALISED
lifetime indicator (202/231/233, or NVMe percentage_used) — a percentage by definition.
Vendor raw counts are still collected and PRINTED WITH THEIR NUMBERS, and may raise a
WARN, but can never drive a FAIL. Attribute 5's raw is now shown beside the normalised
reading that contradicts it, labelled vendor-encoded, with a mechanically-derived
"(= 15 x 4096)". Endurance attributes are matched by THE NAME smartctl's drivedb resolved
for that model, not by bare ID — drivedb is the portability layer; on an unrecognised
drive the name is Unknown_Attribute, nothing matches, and the field stays null with no
claim made. The STORAGE section now prints 170/172/173/174/189/206, whose previous
omission is exactly what let the misread stand unchallenged.
Also documented from TN-FD-20: on this family attr 197 "will always be 0, as reallocation
will be done on-the-fly" — so pending=0 is NOT evidence of health here. The role reports
the number and infers nothing from it.
Branches real hardware cannot exercise were verified with a harness rendering the actual
role expressions against synthetic smartctl payloads: virtio/no-stdout -> SKIP; NVMe
healthy -> PASS; NVMe degraded -> FAIL; a genuinely dying ATA drive (attr 5 normalised 8
<= thresh 10, pending 48) -> FAIL driven by the threshold trip and standard counters, not
the raw; unknown-vendor attrs -> PASS with the unnamed counter ignored; failed-in-the-past
-> WARN.
NEW VERDICTS. k3s-prod-1: 0 FAIL / 4 WARN / 12 PASS / 1 SKIP — SMART is a WARN naming the
real findings (31% of rated life consumed, 15 grown bad blocks, 187 erase failures, 32
unexpected power losses on a drive with no power-loss protection). k3s-dev-1: unchanged,
all three virtio disks still SKIP with their stated reason.
BREAKING (JSON artifact): the fact `reallocated_sectors` is renamed and gone — that name
asserted a unit ATA does not guarantee. Replaced by realloc_attr (the whole attribute,
normalised + raw), realloc_events, and grown_bad_blocks. Nothing in the repo reads it.
Serves: R-ENV-03, R-OBS-04.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
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jakman85andClaude Opus 5
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c1f24e4a6d |
fix(dns): resilient node resolvers — mechanism-detecting, per-environment (R-DNS-01/03)
Re-authors the fix stranded on origin/fix/node-dns-resilient-upstream (
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jakman85andClaude Opus 5
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9f59c36000 |
feat(ansible): node_health role — read-only hardware health for prod + dev nodes
Operator ask: implement the roles needed to check prod node hardware health, and run them to find out our state. This is that role; the run's findings are below. roles/node_health is a read-only sibling to cluster_verify (cluster health vs hardware health), styled after node_baseline. One unprivileged collector script does the work in a single SSH round trip — reading /sys/class/dmi, thermal + hwmon, EDAC, cpufreq + thermal_throttle, /proc/pressure, /sys/block incl. SCSI ioerr/iotmo counters, lsblk, lscpu, mounts + statvfs, per-NIC stats, resolv.conf. THE DESIGN POINT: an unreadable field is emitted as null WITH A RECORDED REASON, never as zero. The summary ends with a "NOT READ (and why) — these are UNKNOWNS, not passes" section. A fake zero on a reallocated-sector count is exactly the kind of false green this project refuses. 22 checks report PASS/WARN/FAIL/SKIP/INFO; every SKIP says why. Report-only by default; thresholds live in defaults/main.yml. Portable across bare metal AND VMs — validated against k3s-prod-1 (bare metal, no root) and k3s-dev-1 (VM, root). VM-absent things (SMART on virtio, coretemp, EDAC) skip cleanly, and iSCSI/Longhorn volumes are split out of the physical-disk set so a live replica is never mistaken for a spare device. playbooks/node-health.yml takes its target group as a variable (-e node_health_hosts= k3s_prod), deliberately unlike the other playbooks that hardcode k3s_servers — see the group-name gap already flagged in hosts.ini. Two become facts found the hard way and documented in the role: a group_vars `ansible_become: true` OUTRANKS `become: false` as a play/task keyword, so unprivileged tasks must override the variable; and `failed_when: false` does NOT catch "Missing sudo password" — only `ignore_errors` does. FIRST RUN, k3s-prod-1, 2026-08-31: 0 FAIL · 3 WARN · 12 PASS · 3 SKIP · 4 INFO. Box is healthy, cool and unstressed: i7-9700T 8C/8T, VT-x + /dev/kvm (KubeVirt OK), zero throttle events, hottest sensor 33C, PSI 0.00 across the board, 31.1 GiB RAM, eno1 up at 1000 Mb/s, BIOS R21 02.26.00, no reboot pending. DRIVE HEALTH IS STILL UNKNOWN — the headline. SMART did not run, blocked TWICE over: no vaulted ansible_become_password for prod, AND smartmontools is not on the node at all (node_baseline has never run there). Power-on hours, wear, reallocated/pending sectors and drive temperature all remain unmeasured on a ~2011 consumer SSD. WARNs: kernel ioerr_cnt=6 on sda (read cautiously — four freshly attached iSCSI disks on dev each showed a flat 7, suggesting a fixed per-device discovery cost, not media trouble; attribution needs dmesg/root); 0.95 GiB swap still active (node_baseline does the swapoff); one IPv4 resolver only (the other two upstreams are IPv6 Google), which refines rather than resolves the DNS-SPOF finding. ESCALATION — ECC status is UNKNOWABLE on this hardware: /sys/devices/system/edac/mc exists but no controller is bound. Non-ECC consumer RAM. Silent memory corruption on a prod node would be undetectable. Recorded as a SKIP with reason, not a pass. Serves: R-ENV-01, R-ENV-03, R-OBS-04. Task: T-7.1. Co-Authored-By: Claude Opus 5 (1M context) <[email protected]> |